Paver with interlocking spacer

ABSTRACT

A paving stone for interlocking with similar adjacent paving stones, having a rectangular block shape. Three single spacers and three spacer pairs extend from the paving stones&#39; lateral surfaces. Each single spacer and each spacer of the spacer pairs have a crest positioned a distance D1 from the lateral surface. Two of the spacer pairs and two of the single spacers are respectively positioned opposite one another on the long lateral surfaces. One of the spacer pairs and one of the single spacers is positioned on the short lateral surfaces. When used with other paving stones having the same features, the single spacers of one paving stone are positioned in troughs of the spacer pairs of another paving stone to provide a structural interlock and create narrow joints between adjacent paving stones. Multiple paving stones can be aligned in multiple configurations, such as herringbone, runner bond, and basketweave patterns.

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to exterior hardscaping. More specifically, the present invention relates to a paving stone for use in roadways, sidewalks, and other hardscaped surfaces to construct permeable surfaces.

2. Description of the Related Art

An interlocking paving block, or paver, is a pre-cast piece of material—typically concrete or clay—that is commonly used in exterior hardscaping applications, such as roads, walkways, patios, pool decks, and driveways. Such pavers are installed over a compacted stone sub-base and a leveling bed of sand.

Instead of connecting the pavers by pouring grout between the joints, as one would do with tiles, sand particles are spread over the pavers and tamped down. The sand stabilizes the interlocking pavers, yet allows for some flexibility. Typical paver hardscapes will absorb the stresses caused by freezes, thaws, and slight ground erosion by shifting each paver slightly. This minimizes cracking or buckling often associated with concrete surfaces.

Interlocking pavers can also be used to construct permeable surfaces. These pavers are configured to maintain open joints or gaps between adjacent pavers. The joints or gaps are filled with a permeable material that allows stormwater to infiltrate down through the surface. The open joints traditionally compromise 5 to 15% of pavement surface and the joints are limited in width to ten-millimeter for compliance with the requirements of the Americans with Disabilities Act. Permeable pavement surfaces are a method to reduce stormwater runoff and water pollution, along with other benefits.

Many modern permeable pavers include spacers, but such spacers do not allow the paver to be arranged in multiple configurations while still providing interlocking functionality from the spacers. For example, U.S. Pat. No. 6,015,243 discloses a paving stone with support attachments arranged on the lateral surfaces. The paving stone includes two attachments on each lateral surface. As shown in FIG. 7 of the '243 patent, movement in one direction parallel to the lateral surface will be resisted by one of the attachments on a lateral surface but not the other attachment, which could cause adjacent paving stones to rotate with respect to each other at the point of contact depending on the strength and direction of the applied force. In other words, interlocking functionality is not provided by all of the attachments on the relevant side in both directions.

U.S. Pat. No. 5,902,069 teaches a paver with identical spacing elements formed around the lateral surfaces of the paver body. Each spacing element is capable of being engaged by an identical but oppositely orientated spacing element or an adjacent paver. One drawback to this technique, however, is that, because each spacing element is identical, the width of the space between the bodies of adjacent stones must be relatively large because each spacer must be wide and deep enough to include a trough and a tooth as well as handle the anticipated stresses that may be applied. It is also more difficult to manufacture the more intricate spacer design raising manufacturing costs.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an improved paving stone with interlocking and self-aligning spacers that, when installed with other similar paving stones, provides a strong structural interlock with a low profile and create relatively narrow joints between adjacent paving stones. The present invention can be aligned in multiple configurations.

Specifically, the present invention comprises a paving stone in the shape of a rectangular solid with a top surface, a bottom surface, opposing long lateral surfaces, and opposing wide lateral surfaces. A single spacer extends from a first wide lateral surface and each of the long lateral surfaces and a spacer pair extends from the second wide lateral surface and each of the long lateral surfaces. The single spacers and spacer pairs are positioned on the lateral surfaces of the paving stone so that the single spacers interlock with the corresponding spacer pairs on a similar adjacent paving stone in multiple paving configurations. More specifically, the position of the single spacers and spacer pairs allow similar adjacent paving stones to be configured in a herringbone pattern, a runner bond pattern, and a basketweave pattern.

Each spacer pair is comprised of two adjacent spacers defining a trough therebetween. Each of the single spacers and spacer pairs are sized and positioned such that a single spacer is positioned within the volume defined by the trough of a corresponding spacer pair of an adjacent paving stone when the paving stones are aligned in a desired pattern. The single spacers and spacer pairs are also sized and configured to ensure a maximum, predetermined gap width between adjacent paving stones.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an isometric view of the preferred embodiment present invention.

FIG. 2 is a top view of the preferred embodiment of the present invention.

FIG. 3 is a side view from line 3-3 of FIG. 2 of the preferred embodiment of the present invention.

FIG. 4 is a top view of a first alternative embodiment of the present invention.

FIG. 5 is a top view of a second alternative embodiment of the present invention.

FIG. 6 is a top view of an exemplar running bond pattern combining multiple paving stones of the present invention.

FIG. 7 is a top view of an exemplar herringbone pattern combining multiple paving stones of the present invention.

FIG. 8 is a top view of an exemplar basketweave pattern combining multiple paving stones of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-3 show a preferred embodiment 20 of the present invention, which comprises a generally rectangular block body 22 having a generally rectangular traversable top surface 24 defined by opposing first and second long sides 26, 28 and first and second wide sides 30, 32. The body 22 includes first and second long lateral surfaces 34, 36 orientated at a right angle relative to the top surface 24, and first and second wide lateral surfaces 38, 40 that are adjacent to the first and second long sides 34, 36. The first and second wide lateral surfaces 33, 40 are also oriented at a right angle relative to both the top surface 24 and the first and second long lateral surfaces. A chamfer surface 33 can be positioned between the top surface 24 and the first and second long lateral surfaces and first and second wide lateral surfaces. The body 22 is symmetrical about a first reference plane P1 which is oriented perpendicular to the top surface 24 and that bisects the first and second wide sides 30, 32 of the top surface 24 with each of the first and second long lateral surfaces 34, 36 being a distance D3 from the first reference plane P1. As used herein, a distance D between an element of the paving stone and lateral surface or between a reference plane and a lateral surface means the shortest perpendicular distance between the lateral surface and a parallel reference plane extending through the element or between the lateral surface and the reference plane. The body 24 is also symmetrical about a second reference plane P2 that bisects the first and second long sides 34, 36 of the top surface 24 and is perpendicular to the first reference plane P1.

A first spacer pair 46 extends from the first wide lateral surface 38 and comprises two adjacent convex spacers 48. Each of the convex spacers has a crest 49 positioned a distance D1 from the first wide lateral surface 38. The two spacers 48 are joined to define a concave trough 50 between them. The trough 50 has a nadir 51 positioned a second distance D2 from the first wide lateral surface 38 and a first trough curvature. As used herein, the nadir is the lowest point of the trough nearest the lateral surface from which the spacer pair extends. Preferably, the nadir 51 is centered on the first wide lateral surface 38 halfway between the first and second long lateral surfaces 34, 36 such that the first reference plane P1 intersects the nadir 51.

Second and third spacer pairs 52, 54 extend from the first and second long lateral surfaces 34, 36, respectively. Each of the second and third spacer pairs 52, 54 comprises two adjacent convex spacers 56. Each of the adjacent convex spacers 56 has a crest 55 positioned a distance D1 from the respective long lateral surfaces 34, 36 from which the spacers 56 extend. The adjacent convex spacers 56 of each spacer pair 52, 54 define second and third concave troughs 58, 59, respectively, each having a nadir 51 positioned a second distance D2 from the respective long lateral surfaces 34, 36 from which the spacer 56 extends. The second and third troughs 58, 59 of the second and third spacer pairs 52, 54 have a second trough curvature and a third trough curvature, respectively. A third reference plane P3 is oriented perpendicular to the top surface 24 and the first reference plane P1 and intersects each nadir 51 of the second and third spacer pairs 52, 54. The third reference plane P3 is positioned a distance D3 from the second wide lateral surface 40.

A first single spacer 60 having a convex surface extends from the second wide lateral surface 40 of the body 22 and has a crest 61. In the preferred embodiment, the crest 61 is positioned a distance D1 from the second wide lateral surface and is centered on the second wide lateral surface halfway between first and second long lateral surfaces 24, 36 such that the first reference pane P1 intersects the crest.

Second and third single spacers 62, 64, each having a convex surface, extend from the first and second long lateral surfaces 34, 36, respectively. Each of said second and third single spacers 62, 64 have crests 63, 65 which are positioned a distance D1 from the respective long lateral surfaces 34, 36 from which the single spacers 62, 64 extend. A fourth reference plane P4, which is perpendicular to the top surface 24 and the first reference plane P1, intersects each of the crests 63, 65 and is positioned a distance D3 from the first wide lateral surface 38.

Preferably, the first, second and third single spacers 60, 62, 64 are symmetric on either side of their respective crests 61, 63, 65. Similarly, the first, second and third spacer pairs 50, 52, 54 are symmetric on either side of their respective nadirs 51. Further, although the first, second and third single spacers 60, 62, 64 and the first, second and third spacer pairs 50, 52, 54 are described with curved convex and concave surfaces, it is also anticipated that these surfaces could be planar such that the cross-sections of the single spacers 60, 62, 64 and each side of the spacer pairs 50, 52, 54 are triangular or trapezoidal as shown in FIGS. 4 and 5, respectively.

The preferred embodiment of the paving stone 20 will have the following relative dimensions:

-   -   (1) the length (L) of each of the first and second long lateral         surfaces 34, 36 is equal to twice the width (W) of a wide         lateral surface 38, 40 plus the width of the gap between two         adjacent, interlocked paving stones. This gap width is equal to         distance D1 plus distance D2 plus the standard clearance C         between a spacer and spacer pair of interlocked paving stones.         As used in the specification and the claims herein, the standard         clearance C shall mean width of the clearance between a single         spacer of one paving stone and a spacer pair of an adjacent         paving stone. The standard clearance is typically 1 mm+/−0.5 mm.         The length L can be calculated by the following: L=2W+D1+D2+C;     -   (2) the distance D3 is equal to one-half of the width (W) of a         wide lateral surface 30, 32 and can be calculated by the         following: D3=W/2;     -   (3) each of the single spacers 60, 62, 64 are identically sized         and shaped;

(4) each of the spacer pairs 50, 52, 54 are identically sized and shaped.

The preferred dimensions of the paving stone 20 are as follows:

-   -   (1) the length (L) of each of the first and second long lateral         surfaces 34, 36 is 244 millimeters;     -   (2) the width (W) of each wide lateral surface 38, 40 is 117 5         millimeters;     -   (3) the distance D1 of each spacer crest from its respective         lateral surface is 6 millimeters;     -   (4) the distance D2 of the nadir 51, 58, 59 of each spacer pair         from its respective lateral surface is 25 millimeters;     -   (5) the width of each single spacer 60, 62, 64 as measured along         its respective long or wide side is 38 millimeters;     -   (6) the width of each spacer pair 50, 52, 54 as measured along         its respective long or wide side is 64 millimeters;     -   (7) the thickness of each paving stone 20 is 80 millimeters.         With these dimensions, the open area between adjacent paving         stones 20 in a combination of multiple paving stones 20 forming         a hardscaped surface area, the open area between the pavers will         be approximately eight percent (8%) of the hardscaped area and         will meet industry standards.

The relative dimensions set forth supra allow a plurality of the paving stones 20 described with reference to FIG. 1-3 to be combined to form a hardscape surface of varying patterns. As shown in FIG. 6, multiple paving stones 20 may be combined into a running bond pattern. Except for those single spacers (not shown) that may be located around the perimeter of hardscape, each single spacer 60, 63, 64 is interlocked with a trough defined by a corresponding spacer pair 46, 52, 54 to inhibit movement of one paving stone 20 with respect to another and insure the preferred spacing between the paving stones 20. As used in the specification and claims herein, “interlocking” or “interlocked” means that a single spacer of one paving stone is positioned within the volume defined by the trough of the corresponding spacer pair similar of an adjacent paving stone with a standard clearance C between the single spacer and corresponding spacer pair.

In the runner bond configuration shown in FIG. 6, the first single spacer 60 of each paving stone 20 is interlocked with the first spacer pair 46 of an adjacent paver. The second single spacer 62 of each paving stone 20 is interlocked with the third spacer pair 54 of an adjacent paving stone 20; and the third single spacer 64 of each paving stone 20 is interlocked with the second spacer pair 52 of an adjacent paving stone 20.

As shown in FIG. 7, multiple paving stones 20, 20’ may be combined into a herringbone pattern. In this configuration, the paving stones 20 are all aligned in a first direction in a series of stepped patterns such that the second single spacer 62 of each paving stone 20 is interlocked with the third spacer pair 54 of an adjacent paving stone 20. The paving stones 20′ are all aligned in a second direction which is perpendicular to the first direction and are also aligned in a series of stepped patterns such that the third single spacer 64′ of each paving stone 20′ is interlocked with the second spacer pair 52′ of an adjacent paving stone 20′.

Also, in this configuration, each of the paving stones 20 interlock with adjacent paving stones 20′ as follows: (1) the first single spacer 60′ of each paving stone 20′ interlocks with the second spacer pair 52 of a paving stone 20; (2) the second single spacer 62′ of each paving stone 20′ interlocks with the first spacer pair 46 of a paving stone 20; (3) the first spacer pair 46′ of each paving stone 20′ interlocks with the third single spacer 64 of a paving stone 20; and (4) the third spacer pair 54′ of each paving stone 20′ interlocks with the first single spacer 60 of a paving stone 20.

As shown in FIG. 8, multiple paving stones 20, 20′ may also be combined into a basketweave pattern. In this configuration, two paving stones 20 oriented in a first direction are arranged with their long sides 23 being adjacent such that the third single spacer 64 of each paving stone 20 interlocks with the third spacer pair 54 of the adjacent paving stone 20. In this manner, a set of paving stones 20 oriented in a first direction is formed.

Also in this configuration, two paving stones 20′, oriented in a second direction, are also arranged with their long sides 28′ being adjacent such that the third single spacer 64′ of each paving stone 20′ interlocks with the third spacer pair 54′ of the adjacent paving stone 20′. In this manner, another set of paving stones 20′ is formed oriented in a second direction which is perpendicular to the first direction. To complete the basketweave pattern, additional sets of paving stones 20 and sets of paving stones 20′ are arranged in an alternating checkerboard pattern as shown in FIG. 8.

In this basketweave configuration, each of the paving stones 20 interlock with adjacent paving stones 20′ as follows: (1) the first single spacer 60 of each paving stone 20 interlocks with second spacer pair 52′ of a paving stone 20′; (2) the second single spacer 62 of each paving stone 20 interlocks with the first spacer pair 46′ of a paving stone 20′; (3) the first spacer pair 46 of each paving stone 20 interlocks with the second single spacer 62′ of a paving stone 20′; and (4) the second spacer pair 52 of each paving stone 20 interlocks with the first single spacer 62′ of a paving stone 20′.

The present invention is described above in term of a preferred illustrative embodiment of a specifically-described paving stone. Those skilled in the art will recognize that alternative constructions of such an apparatus can be used in carrying out the present invention. Other aspects, features, and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims. 

I claim:
 1. A paving stone for interlocking with a similar adjacent paving stone, said paving stone comprising: a top surface having a first long side, a second long side opposing the first long side, a first wide side, and a second wide side opposing the first wide side; a first long lateral surface and an opposing second long lateral surface, each being perpendicular to the top surface; a first wide lateral surface and an opposing second wide lateral surface, each being perpendicular to the top surface and said first and second long lateral surfaces; a first spacer pair extending from the second first wide lateral surface and having an outer surface; said first spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from the first wide lateral surface and defining a first trough therebetween; said first trough having nadir at said outer surface positioned a second distance D2 from the first wide lateral surface; a second spacer pair extending from said first long lateral surface and having an outer surface; said second spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from said first long lateral surface and defining a second trough therebetween; said second trough having a nadir at said outer surface positioned a second distance D2 from said first long lateral surface; a third spacer pair extending from the second long lateral surface and having an outer surface; said third spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from said second longer lateral surface and defining a third trough therebetween; said third trough having nadir at said outer surface positioned a second distance D2 from said second long lateral surface; a first single spacer extending from the second wide lateral surface and having an outer surface; said first single spacer with a crest positioned a perpendicular distance D1 from said second wide lateral surface; a second single spacer extending from said first long lateral surface; said second single spacer having an outer surface with a crest positioned a perpendicular distance D1 from said first long lateral surface; a third single spacer extending from said second long lateral surface; said third single spacer having an outer surface with a crest positioned a perpendicular distance D1 from the second long lateral surface.
 2. The paving stone of claim 1 further comprising a chamfer surface bordering said top surface and adjacent to said first long lateral surface, said second long lateral surface, said first wide lateral surface, and said second wide lateral surface.
 3. The paving stone of claim 1 wherein the first single spacer is centered on said second wide lateral surface so that said crest is positioned a perpendicular distance D3 from each of said first and second long lateral surfaces; and wherein said first spacer pair is centered on the first wide lateral surface so that the nadir of said first trough is positioned a perpendicular distance D3 from each of said first and second long lateral surfaces.
 4. The paving stone as recited in claim 3 wherein each of the crests of the second and third single spacers are a perpendicular distance D3 from the first wide lateral surface.
 5. The paving stone as recited in claim 4 wherein each of the nadirs of said second and third troughs of said second and third spacer pairs are positioned a perpendicular distance D3 from said second wide lateral surface.
 6. The paving stone of claim 1 wherein the length of each of the first and second long lateral surfaces is substantially equal to twice the width of the first wide lateral surface plus the width of a gap created between said paving stone and a similar adjacent interlocking paving stone.
 7. The paving stone as recited in claim 6 wherein said gap is substantially equal to said distance D1 plus said distance D2 plus a standard clearance C.
 8. The paving stone as recited in claim 7 wherein said standard clearance C is 1.0 mm+/−0.5 mm.
 9. The paving stone of claim 7 wherein said gap is less than or equal to ten millimeters.
 10. The paving stone of claim 1 wherein said outer surface of each of said first, second and third single spacers and each spacer of said first, second and third spacer pairs has a convex curvature; and wherein each of said first, second and third troughs has a concave curvature.
 11. The paving stone as recited in claim 1 wherein the outer surface of said first, second and third single spacers and said first, second and third spacer pairs is formed of planar surfaces and wherein said first, second and third single spacers have a triangular cross-section and each spacer of said first, second and third spacer pairs has a triangular cross-section.
 12. The paving stone as recited in claim 1 wherein the outer surface of said first, second and third single spacers and said first, second and third spacer pairs is formed of planar surfaces and wherein said first, second and third single spacers have a trapezoidal cross-section and each spacer of said first, second and third spacer pairs has a trapezoidal cross-section.
 13. A system of arranged paving stones forming a paved surface, said system comprising: a plurality of paving stones with each paving stone comprising: a top surface having a first long side, a second long side opposing the first long side, a first wide side, and a second wide side opposing the first wide side; a first long lateral surface and an opposing second long lateral surface, each being perpendicular to the top surface; a first wide lateral surface and an opposing second wide lateral surface, each being perpendicular to the top surface and said first and second long lateral surfaces; a first spacer pair extending from the first wide lateral surface and having an outer surface; said first spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from the first wide lateral surface and defining a first trough therebetween; said first trough having nadir at said outer surface positioned a second distance D2 from the first wide lateral surface; a second spacer pair extending from said first long lateral surface and having an outer surface; said second spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from said first long lateral surface and defining a second trough therebetween; said second trough having a nadir at said outer surface positioned a second distance D2 from said first long lateral surface; a third spacer pair extending from the second long lateral surface and having an outer surface; said third spacer pair comprising two adjacent spacers each having a crest at said outer surface positioned a first distance D1 from said second longer lateral surface and defining a third trough therebetween; said third trough having nadir at said outer surface positioned a second distance D2 from said second long lateral surface; a first single spacer extending from the second wide lateral surface and having an outer surface; said first single spacer with a crest positioned a perpendicular distance D1 from said second wide lateral surface; a second single spacer extending from said first long lateral surface; said second single spacer having an outer surface with a crest positioned a perpendicular distance D1 from said first long lateral surface; a third single spacer extending from said second long lateral surface; said third single spacer having an outer surface with a crest positioned a perpendicular distance D1 from the second long lateral surface; and wherein each of said paving stones is positioned adjacent to and interlocked with at least one other paving stone.
 14. The system of arranged paving stones of claim 13 wherein: said first single spacer is centered on said second wide lateral surface so that its crest is positioned a perpendicular distance D3 from each side of said first and second long lateral surfaces; said first spacer pair is centered on the first wide lateral surface so that the nadir of said first trough is positioned a perpendicular distance D3 from each of said first and second long lateral surfaces; each of the crests of said second and third single spacers are a perpendicular distance D3 from the first wide lateral surface; and each of the nadirs of said second and third troughs of said second and third spacer pairs are positioned a perpendicular distance D3 from said second wide lateral surface.
 15. The system of arranged paving stones of claim 13 wherein the length of each of the first and second long lateral surfaces of a paving stone is substantially equal to twice the width of the first wide lateral surface plus the width of a gap created between two adjacent interlocking paving stones.
 16. The system of arranged paving stones as recited in claim 15 wherein said gap is substantially equal to said distance D1 plus said distance D2 plus a standard clearance C.
 17. The system of arranged paving stones as recited in claim 16 wherein said standard clearance is one millimeter +/− one-half millimeter.
 18. The system of arranged paving stones as recited in claim 17 wherein said gap is less than or equal to ten millimeters.
 19. The system of arranged paving stones as recited in claim 13 wherein said outer surface of each of said first, second and third single spacers and each spacer of said first, second and third spacer pairs has a convex curvature and wherein of each of said first, second and third troughs has a concave curvature.
 20. The system of arranged paving stones as recited in claim 13 wherein the outer surface of said first, second and third single spacers and said first, second and third spacer pairs is formed of planar surfaces and wherein said first, second and third single spacers have a triangular cross-section and each spacer of said first, second and third spacer pairs has a triangular cross-section.
 21. The system of arranged paving stones as recited in claim 13 wherein the outer surface of said first, second and third single spacers and said first, second and third spacer pairs is formed of planar surfaces and wherein said first, second and third single spacers have a trapezoidal cross-section and each spacer of said first, second and third spacer pairs has a trapezoidal cross-section.
 22. The system of arranged paving stones as recited in claim 13 wherein said plurality of paving stones are arranged in a runner bond pattern.
 23. The system of arranged paving stones as recited in claim 13 wherein the plurality of paving stones are arranged in a herringbone pattern.
 24. The system of arranged paving stones as recited in claim 13 wherein the plurality of paving stones are arranged in a basketweave pattern. 